Mansoura University

Faculty of Engineering
Prod. Eng. & Mech. Design Dept.

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 Mansoura University Quality Control [PRE5422]
Faculty of Engineering Prod. & Mech. Design Eng. Program
Prod. & Mech. Design Eng. Dept. 2nd Year – 2nd Term 2023/2024

Exercise No. 1 ― Control Charts for Variables

Q1) Control charts for 𝑋̅ and R are to be established on a certain dimension part,
measured in millimeters. Data were collected in subgroup sizes of 6 and are given
below. Determine the trial central line and control limits. Assume assignable causes
and revise the central line and limits.

Subgroup ̅ Subgroup ̅
𝑿 R 𝑿 R
Number Number
1 20.35 0.34 14 20.41 0.36
2 20.40 0.36 15 20.45 0.34
3 20.36 0.32 16 20.34 0.36
4 20.65 0.36 17 20.36 0.37
5 20.20 0.36 18 20.42 0.73
6 20.40 0.35 19 20.50 0.38
7 20.43 0.31 20 20.31 0.35
8 20.37 0.34 21 20.39 0.38
9 20.48 0.30 22 20.39 0.33
10 20.42 0.37 23 20.40 0.32
11 20.39 0.29 24 20.41 0.34
12 20.38 0.30 25 20.40 0.30
13 20.40 0.33

Q2) Control charts for 𝑋̅ and s are to be established on the Brinell hardness of
hardened tool steel in kilograms per square millimeters. Data for subgroup size of 8
are shown below. Determine the trial central line and control limits for the 𝑋̅ and s
charts. Assume that the out-of-control points have assignable causes. Calculate the
revised limits and central line.

Subgroup ̅ Subgroup ̅
𝑿 s 𝑿 S
Number Number
1 540 26 14 551 24
2 534 23 15 522 29
3 545 24 16 579 26
4 561 27 17 549 28
5 576 25 18 508 23
6 523 50 19 569 22
7 571 29 20 574 28
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 8 457 29 21 563 33
9 584 23 22 561 23
10 552 24 23 548 25
11 541 28 24 556 27
12 545 25 25 553 23
13 546 26

Q3) Control charts for 𝑋̅ and s are maintained on the resistance in Ohms of an
electrical part. The subgroup size is 6. After 25 subgroups, ∑ 𝑋̅ = 2046.5 and ∑ 𝑠 =
17.4. If the process is in statistical control, what are the control limits and central
line?

Q4) Plastic strips that are used in a sensitive electronic device are manufactured to a
maximum specification of 305.70 mm and a minimum specification of 304.55 mm. If
the strips are less than the minimum specification, they are scrapped; if they are
greater than the maximum specification, they are reworked. The part dimensions are
normally distributed with a population mean of 305.20 mm and a standard deviation
of 0.25 mm. What percentage of the product is scrap? What percentage is rework?
How can the process be centered to eliminate all but 0.1% of the scrap? What is the
rework percentage now?

Q5) A company that manufactures oil seals found the population mean to be 49.15
mm, the population standard deviation to be 0.51 mm, and the data to be normally
distributed. If the internal diameter of the seal is below the lower specification limit
of 47.80 mm, the part is reworked. However, if it is above the upper specification
limit of 49.80 mm, the seal is scrapped. (a) What percentage of the seals is reworked?
What percentage is scrapped? (b) For various reasons, the process average is changed
to 48.50 mm. With this new mean or process center, what percentage of the seals is
reworked? What percentage is scrapped? If rework is economically feasible, is the
change in the process center a wise decision?

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Quality Control 2nd Term – 23/24